Mattress assembly

ABSTRACT

A mattress assembly includes a foundation that defines first and second axes oriented along the length and the width of the foundation, respectively. The mattress assembly further includes a mattress supported atop the foundation and means for securing the mattress to the foundation to inhibit sliding movement of the mattress relative to the foundation along at least one of the first and second axes.

FIELD OF THE INVENTION

The present invention relates to mattresses, and more particularly tomattress and foundation assemblies.

BACKGROUND OF THE INVENTION

Conventional mattresses can be found in a wide variety of shapes andsizes. Many mattresses are constructed entirely or partially out of foammaterial, For example, polyurethane foam is commonly used in manymattresses, pillows, and cushions, and can be used alone or incombination with other types of cushion materials. In some mattresses,viscoelastic material is used, providing the mattress with an increasedability to conform to a user and to distribute the weight of the user.

Mattresses are typically supported by foundations (e.g., frames,box-springs, etc.), relying on the weight of the mattress and theresultant friction between the mattress and the foundation to preventthe mattress from moving relative to the foundation. However, after aperiod of normal use, mattresses may slip relative to their foundationsand require repositioning. This problem may be exacerbated in the caseof an adjustable foundation.

Based at least in part upon the limitations of existing mattresses andthe high consumer demand for improved mattresses in a wide variety ofapplications, new mattresses are welcome additions to the art.

SUMMARY OF THE INVENTION

The invention provides, in one aspect, a mattress assembly including afoundation that defines first and second axes oriented along the lengthand the width of the foundation, respectively. The mattress assemblyfurther includes a mattress supported atop the foundation and means forsecuring the mattress to the foundation to inhibit sliding movement ofthe mattress relative to the foundation along at least one of the firstand second axes.

Other features and aspects of the invention will become apparent byconsideration of the following detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a mattress assembly according to anembodiment the invention.

FIG. 2 is an enlarged view of a latch of the mattress assembly of FIG.1.

FIG. 3 is a perspective view of a mattress assembly according to anotherembodiment of the invention.

FIG. 4 is a cross-sectional view of a magnet of the mattress assembly ofFIG. 3.

FIG. 5 is a partial perspective view of a mattress assembly according toyet another embodiment of the invention.

FIG. 6 is a partial top view of a securing assembly of the mattressassembly of FIG. 5.

FIG. 7 is a cross-sectional view of a pocket of the securing assembly ofFIG. 6

FIG. 8 is a side view of a projection of the securing assembly of FIG.6.

FIG. 9 is a cross-sectional view of a mattress assembly according to afurther embodiment of the invention.

FIG. 10 is a top view of a foundation of the mattress assembly of FIG.9.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the accompanyingdrawings, The invention is capable of other embodiments and of beingpracticed or of being carried out in various ways. Also, it is to beunderstood that the phraseology and terminology used herein is for thepurpose of description and should not be regarded as limiting,

DETAILED DESCRIPTION

FIG. 1 illustrates a mattress assembly 108 according to one embodimentof the invention including a mattress 110 and a foundation 111. Thefoundation 111 defines first and second orthogonal axes 116, 118oriented along the length and the width of the foundation 111,respectively, The mattress 110 illustrated in FIG. 1 includes a topsurface 112 positioned to support a user and a bottom surface 114 thatrests directly upon the foundation 111. The foundation 111 may include aframe, support, box-spring, or other structure suitable for supportingthe weight of the mattress 110 and user(s) thereon. The mattress 110 mayinclude one or more layers of foam material, although one or more layersof other material may be used instead or in addition to the foam layers,if desired. The material comprising one or more of the foam layers mayinclude, for example, viscoelastic or non-viscoelastic foam, latex foam,any expanded polymer (e.g., expanded ethylene vinyl acetate,polypropylene, polystyrene, Or polyethylene), and the like. In theillustrated embodiment of FIG. 1, the mattress 110 has only a singleviscoelastic foam layer, and the top and bottom surfaces 112, 114 of themattress 110 are substantially planar. Alternatively, multipleviscoelastic or non-viscoelastic foam layers may be used, and either orboth of the top and bottom surfaces 112, 114 may include one or moreconvolutions or other non-planar shapes.

With continued reference to FIG. 1, the viscoelastic foam in themattress 110 includes a cellular structure in which the walls of theindividual cells are substantially intact (Le. non-reticulatedviscoelastic foam). In other embodiments, the viscoelastic foam may bereticulated. Reticulated viscoelastic foam has characteristics that arewell suited for use in the mattress 110, including an enhanced ability(i.e., when compared to non-reticulated viscoelastic foam) to permit themovement of an therethrough, thereby providing enhanced air and/or heatmovement within, through, and away from the viscoelastic foam.Reticulated foam is a cellular foam structure in which the cells of thefoam are essentially skeletal. In other words, the cells of thereticulated foam are each defined by a plurality of apertured windowssurrounded by cell struts. The tell windows of reticulated foam can beentirely gone (leaving only the cell struts) or substantially gone. Insome embodiments, the foam is considered “reticulated” if at least 50%of the windows of the cells are missing (i.e., windows having aperturestherethrough, or windows that are completely missing and thereforeleaving only the cell struts). Such structures can be created bydestruction or other removal of cell window material, or preventing thecomplete formation of cell windows during the manufacturing process ofthe foam.

The viscoelastic foam in the mattress 110 provides a relativelycomfortable substrate for a user's body, can at least partially conformto the user's body to distribute force applied thereby, and can beselected for responsiveness to a range of temperatures generated by thebody heat of a user. The viscoelastic foam layer of the mattress 110provides a relatively soft and comfortable surface for a user's body orbody portion (hereinafter referred to as “body”). in some embodiments,the viscoelastic foam in the mattress 110 has a hardness of at leastabout 20 N and no greater than about 80 N for desirable softness andbody-conforming qualities. In other embodiments, the viscoelastic foammay have a hardness of at least about 30 N and no greater than about 70N. In still other embodiments, the viscoelastic foam may have a hardnessof at least about 40 N and no greater than about 60 N. Unless otherwisespecified, the hardness of any foam material referred to herein ismeasured by exerting pressure from a plate against a sample of thematerial to a compression of 40% of an original thickness of thematerial at approximately room temperature (e.g., 21-23 DegreesCelsius), wherein the 40% compression is held for a set period of timefollowing the International Organization of Standardization (ISO) 2439hardness measuring standard.

The viscoelastic foam in the mattress 110 also includes a densityproviding a relatively high degree of material durability. The densityof the viscoelastic foam in the mattress 110 can also impact othercharacteristics of the foam, such as the manner in which mattress 110responds to pressure, and the feel of the foam. In some embodiments, theviscoelastic foam in the mattress 110 has a density of no less thanabout 30 kg/m³ and no greater than about 150 kg/m³. In otherembodiments, the viscoelastic foam may have a density of at least about40 kg/m³ and no greater than about 135 kg/m³. In still otherembodiments, the viscoelastic foam may have a density of at least about50 kg/m³ and no greater than about 120 kg/m³.

With reference to FIG. 1, the mattress 110 and the foundation 111 aresubstantially rectangular, having four sides. Alternatively, themattress 110 and/or the foundation 111 may be configured having anynumber of different shapes and therefore, sides.

With continued reference to FIGS. 1 and 2, the mattress assembly 108further includes a securing assembly 120 configured to secure themattress 110 to the foundation III. The securing assembly 120 inhibitssliding movement of the mattress 110 relative to the foundation 111along at least one of the first and second axes 116, 118, The securingassembly 120 may include latches, magnets, fittings, or any otherstructure configured to inhibit sliding movement of the mattress 110relative to the foundation 111, depending on the particular embodimentbeing described. In the embodiment illustrated in FIGS. 1 and 2, thesecuring assembly 120 includes a plurality of latches 124 coupling themattress 110 to the foundation 111.

With reference to FIG. 2, each of the latches 124 includes a buckle 128attached to the mattress 110 and a catch 132 attached to the foundation111. Alternatively, the buckle 128 may be attached to the foundation111, and the catch may be attached to the mattress 110. The catch 132 inengageable with the buckle 128 to secure the mattress 110 to thefoundation 111. The buckle 128 may be formed as a separate piece andattached to the mattress 110 by any suitable method, such as withstitches. Similarly, the catch 132 may be formed as a separate piece andattached to the foundation 111 by any suitable method, such as withfasteners 140. In other embodiments, the buckle 128 may be integrallyformed with the mattress 110 and the catch 132 may be integrally formedwith the foundation 111. In still other embodiments, one of the buckle128 and the catch 132 may be formed as a separate piece and the other ofthe buckle 128 and the catch 132 may he integrally formed with themattress 110 or the foundation 111, respectively,

The latch 124 may be formed from a flexible material, such as apolymeric material. The elastic properties of the flexible materialfacilitates engaging and disengaging the latch 124, and the latch 124can be configured such that an elastic recovery force biases latch 124toward an engaged position and inhibits inadvertent disengagement of thelatch 124. In other embodiments, one or more components of the latch 124may be a rigid material. In such embodiments, elastic properties, of themattress 110 or the foundation 111 may produce an elastic recovery forceas described above, when the latch 124 is in the engaged position.

In the embodiment illustrated in FIGS. 1 and 2, the securing assembly120 includes a latch 124 associated with each side of the mattress 110and the foundation 111 to inhibit sliding movement of the mattress 110relative to the foundation 111 along both axes 116, 118, Alternatively,fewer latches 124 (e.g., two latches 124) may be used As such thesecuring assembly 120 may include any number of latches 124 arrangedalong any combination of sides of the mattress 110 and the foundation111.

FIGS. 3 and 4 illustrate a mattress assembly 208 according to anotherembodiment of the invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiment of themattress assembly 108 described above in connection with FIGS. 1 and 2.Accordingly, the following description focuses primarily upon thestructure and features that are different than the embodiment describedabove in connection with FIGS. 1 and 2. Reference should he made to thedescription above in connection with FIGS. 1 and 2 for additionalinformation regarding the structure and features, and possiblealternatives to the structure and features of the mattress assembly 208illustrated in FIGS. 3 and 4 and described below. Structure and featuresof the embodiment Shown in FIGS. 3 and 4 that correspond to structureand features of the embodiment of FIGS. 1 and 2 are designatedhereinafter in the 200 series of reference numbers.

With reference to FIG. 3, the mattress assembly 208 includes a mattress210 and a foundation 211. The foundation 211 defines first and secondorthogonal axes 216, 218 oriented along the length and the width of thefoundation 211, respectively. The mattress 210 illustrated in FIG. 3includes a top surface 212 positioned to support a user and a bottomsurface 214 that rests directly upon the foundation 211. The foundation211 may include a frame, support box-spring, or other structure suitablefor supporting the weight of the mattress 210 and user(s) thereon. Themattress 210 may include one or more layers of foam material (e.g.,viscoelastic foam), although the mattress 210 may also include one ormore layers of other material, if desired, In the illustrated embodimentthe mattress 210 ha only a single viscoelastic foam layer, and the topand bottom surfaces 212, 214 of the mattress 210 are substantiallyplanar.

In the embodiment illustrated in FIG. 3, the mattress 210 and thefoundation 211 are substantially rectangular, having four sides.Alternatively, the mattress 210 and/or the foundation 211 may beconfigured having any number of different shapes and therefore, sides.

With continued reference to FIG. 3, the mattress assembly 208 furtherincludes a securing assembly 220 configured to secure the mattress 210to the foundation 211. The securing assembly 220 inhibits slidingmovement of the mattress 210 relative to the foundation 211 along thefirst and second axes 216, 218. In the illustrated embodiment, thesecuring assembly 220 includes a plurality of magnets 244 a, 244 b thatare magnetically latchable to couple the mattress 210 to the foundation211.

In the illustrated embodiment, the magnets 244 a, 244 b, are permanentmagnets, generating their own persistent magnetic fields, The magnets244 a, 244 b may be any suitable type of permanent magnet (e.g.,ferrite, alnico, samarium-cobalt, neodymium, etc.). Alternatively, themagnets 244 a, 244 b may be electromagnets and may selectively generatemagnetic fields is response to an applied electrical current.

With reference to FIG. 4, the foundation 211 includes a fabric cover 248secured to an underlying frame not shown) of the foundation 211 by anysuitable method (e.g., stitches, staples, elastic elements, adhesives,etc.), In the illustrated embodiment, half of the plurality of magnets(referred to hereafter as the lower magnets 244 a) are sewn into thecover 248 (e.g., between two layers of the cover 248), In someembodiments, the foundation 211 may not include a fabric cover 248, andthe lower magnets 244 a may be glued to the foundation 211 by a suitableadhesive, In other embodiments, the lower magnet 244 a may be sewndirectly to the foundation 211. With reference to FIG. 3, the remaininghalf of the magnets (referred to hereafter as the upper magnets 244 b)are secured to the mattress 210 in positions corresponding to thepositions of the lower magnets 244 a on the foundation 211, The uppermagnets 244 b are oriented so as to promote magnetic attraction betweenthe upper magnets 244 b and the lower magnets 244 a, The upper magnets244 b may be secured to the mattress 210 by any suitable method, such asthose described above with reference to the lower magnets 244 a.Accordingly, when the mattress 210 is placed atop the foundation 211,the upper and lower magnets 244 b, 244 a become magnetically latched andinhibit sliding movement of the mattress 210 relative to the foundation211 along the first and second axes 216, 218.

In the illustrated embodiment, the upper and lower magnets 244 b, 244 aare respectively arranged along opposing sides of the mattress 210 andthe foundation 211 corresponding to the length dimension of the mattress210 and the foundation 211. Alternatively, the plurality of magnets 244may be arranged in any way, including but not limited to around theperimeter of the mattress 210 and the foundation 211, in an S, Z, or Xshaped pattern, in a plurality of parallel rows and columns, or in aseries of concentric rectangles. In addition, any number of magnets 244a, 244 b may be used.

FIGS. 5-8 illustrate a mattress assembly 308 according to anotherembodiment of the invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of themattress assemblies 108 and 208 described above in connection with FIGS.1-4. Accordingly, the following description focuses primarily upon thestructure and features that are different than the embodiments describedabove in connection with FIGS. 1-4. Reference should be made to thedescription above in connection with FIGS. 1-4 for additionalinformation regarding the structure and features, and possiblealternatives to the structure and features of the mattress assembly 308illustrated in FIGS. 3-8 and described below. Structure and features ofthe embodiment shown in FIGS. 5-8 that correspond to structure andfeatures of the embodiments of FIGS. 1-4 are designated hereinafter inthe 300 series of reference numbers.

With reference to FIG. 5, the mattress assembly 308 includes a mattress310 and a foundation 311. The foundation 311 defines first and secondorthogonal axes 316, 318 oriented along the length and the width of thefoundation 311, respectively. The mattress 310 illustrated in FIG. 5includes a top surface 312 positioned to support a user and a bottomsurface 314 that rests directly upon the foundation 311. The foundation311 may include a frame, support, box-spring, or other structuresuitable for supporting the weight of the mattress 310 and user(s)thereon. The mattress 310 may include one or more layers of foammaterial (e.g., viscoelastic foam), although the mattress 310 may alsoinclude one or more layers of other material, if desired. In theillustrated embodiment, the mattress 310 has only a single viscoelasticfoam layer, and the top and bottom surfaces 312, 314 of the mattress 310are substantially planar.

In the embodiment illustrated in FIG. 5. the mattress 310 and thefoundation 311 are substantially rectangular, having four sides.Alternatively, the mattress 310 and/or the foundation 311 may beconfigured having any number of different shapes and therefore, sides.

With continued reference to FIG. 5, the mattress assembly 308 furtherincludes a securing assembly 320 configured to secure the mattress 310to the foundation 311. The securing assembly 320 inhibits slidingmovement of the mattress 310 relative to the foundation 311 along thefirst and second axes 316, 318. In the illustrated embodiment, thesecuring assembly 320 includes a rigid projection 352 insertable into apocket 356 to couple the mattress 310 to the foundation 311.

With reference to FIG. 5, the rigid projection 352 is a bar including amiddle portion 360 and end portions 364 a, 364 b attached the foundation311 by conventional fasteners 340 (FIG. 8). The bar 352 is formed from arigid material (e.g., steel, aluminum, ABS, FIDPE, PVC, etc.) in orderto resist sliding movement of the mattress 310 relative to thefoundation 311 without bending. The pocket 356 comprises a textile orpolymeric rectangle sewn along three sides, onto the bottom surface 314of the mattress 310 (FIG. 5). The pocket 356 is configured to snuglyreceive the middle portion 360 of the projection 352. Alternatively, theprojection 352 may be associated with the mattress 310 and the pocket356 may be associated with the foundation 311. In other embodiments, theprojection 352 and the pocket 356 may be any other type of cooperatingstructure, and may be attached to the foundation 311 and the mattress310 with fasteners, adhesive, staples, stitches, or any other suitablestructure or process. In still other embodiments, the projection 352and/or the pocket 356 may be integrally formed with the foundation 311and the mattress 310, respectively.

In the embodiment illustrated in FIG. 5, the projection 352 and thepocket 356 are each disposed along a side of the foundation 311 and themattress 310 corresponding with the respective widths of the foundation311 and the mattress 310. In other embodiments, the projection 352 andthe pocket 356 may be arranged along any of the sides.

FIGS. 9 and 10 illustrate a mattress assembly 408 according to anotherembodiment of the invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of themattress assemblies 108, 208, and 308 described above in connection withFIGS. 1-8. Accordingly, the following description focuses primarily uponthe structure and features that are different than the embodimentsdescribed above in connection with FIGS. 1-8, Reference should be madeto the description above in connection with FIGS. 1-8 for additionalinformation regarding the structure and features, and possiblealternatives to the structure and features of the mattress assembly 408illustrated in FIGS. 9 and 10 and described below. Structure andfeatures of the embodiment shown in FIGS. 9 and 10 that correspond tostructure and features of the embodiments of FIGS. 1-8 are designatedhereinafter in the 400 series of reference numbers.

With reference to FIG. 9, the mattress assembly 408 includes a mattress410 and a foundation 411. The foundation 411 defines first and secondorthogonal axes 416, 418 (FIG. 10) oriented along the length and thewidth of the foundation 411, respectively. The mattress 410 illustratedin FIG. 9 includes a top surface 412 positioned to support a user and abottom surface 414 that rests directly upon the foundation 411. Thefoundation 411 may include a frame, support, box-spring, or otherstructure suitable for supporting the weight of the mattress 410 anduser(s) thereon. The mattress 410 may include one or more layers of foammaterial (e.g., viscoelastic foam), although the mattress 410 may alsoinclude one or more layers of other material, if desired. In theillustrated embodiment, the mattress 410 has only a single viscoelasticfoam layer, and the top and bottom surfaces 412, 414 of the mattress 410are substantially planar.

In the embodiment illustrated in FIGS. 9 and 10, the mattress 410 andthe foundation 411 are substantially rectangular, having four sides.Alternatively, the mattress 410 and/or the foundation 411 may beconfigured having any number of different shapes and therefore, sides.

The mattress 410 can include an internal chamber 464 that can bepartially or fully occupied by reticulated foam (whether viscoelastic orotherwise), or that can instead be substantially empty. Airflow may begenerated through the internal chamber 464 at times when cooling of themattress 410 is needed. The internal chamber 464 may have any shape andsize desired, and may be defined by a number of cavities and voidsextending to various locations within the mattress 410. In someembodiments, the mattress 410 may have a series or cluster of internalchambers 464 each having any shape desired (e.g., round, oval,elliptical, or otherwise rotund internal chambers, internal chamberseach having a square, triangular, or other polygonal shape, elongatedinternal chambers each having an S-shape, shape, or other shape,internal chambers having an irregular shape, internal chambers havingany combination of such shapes, and the like). Also, any number of theinternal chambers 464 may be coupled together and can thereby be influid communication with one another.

In the illustrated embodiment of FIG. 9, the internal chamber 464extends to a first cavity 468 in the mattress 410, in fluidcommunication with the internal chamber 464. When the mattress 410 ispositioned upon the foundation 411, the first cavity 468 aligns with asecond cavity 472 in the foundation 411. In the illustrated embodiment,the first and second cavities 468, 472 have a square cross-section;however, in other embodiments, the first and second cavities 468, 472can have any other shape (e.g., round, rectangular, hexagonal, etc.). Afitting 476 (see also FIG. 10) corresponding to the shape of the firstand second cavities 468, 472 is anchored to the foundation 411 andincludes a tapered end 480 to facilitate alignment of the first andsecond cavities 468, 472 when the mattress 410 is placed upon thefoundation 411. Alternatively, the fitting 476 may be anchored to themattress 410. The fitting 476 includes a flexible material, such as aflexible polymer, metal or other similar flexible material toaccommodate a greater tolerance in the relative position of the firstand second cavities 468, 472. In some embodiments, the fitting 476 mayextend at least partially into the internal chamber 464.

With reference to FIG. 9, a fan 484 is positioned in the second cavity472 and is operable to generate an airflow through the internal chamber646, The fan 484 may include any number of fan blades, and can take anyform desired, including an axial fan, a centrifugal fan, and the like.In other embodiments, the fan 484 may be omitted.

The second cavity 472 can function as an outlet for the airflow createdby the fan 484. In some embodiments, the fan 484 may be retained in thisposition within the foundation 411 by compressive force of thefoundation 411 surrounding the fan 484 or by the fitting 476. Thefitting 476 and internal chamber 464 form a duct to provide fluid flowthroughout the mattress assembly 408.

In the illustrated embodiment, the fan 484 is positioned in thefoundation 411, below the bottom surface 414 of the mattress 41 aPositioning the fan 484 in the foundation 411 can present the advantageof at least partially isolating the user from noise and vibration causedby fan operation. Embodiments in which the fan 484 is positioned in thefoundation 411 also permit a user to select a mattress 410 and afoundation 411 separately, such that any suitable mattress 410 can besupported upon the foundation 411, and any foundation 411 can be used tosupport the mattress 410. In other embodiments, the fan 484 may belocated in other positions, such as immediately adjacent the internalchamber 464, immediately adjacent the bottom surface 414 of the mattress410, and the like. In still other embodiments, the fan 484 may bepositioned at least partially in the internal chamber 464 of themattress 410.

With reference to FIG. 10, the fitting 476 is one of a plurality offittings 476 extending from the foundation 411. The fittings 476function as a securing assembly 420 to secure the mattress 410 to thefoundation 411. In other embodiments, any number and arrangement offittings 476 may be included. Interference between the fittings 476 andthe cavities 468, 472 inhibits sliding movement of the mattress 410relative to the foundation 411 along the first and second axes 416, 418.

Various features of the invention are set forth in the following claims.

1-30. (canceled)
 31. A mattress assembly comprising: a foundationdefining first and second axes oriented along the length and the widthof the foundation, respectively; a mattress supported atop thefoundation; and an alignment fitting extending from one of thefoundation and the mattress, and a cavity defined in the other of thefoundation and the mattress in which the fitting is inserted forcoupling the mattress to the foundation to inhibit sliding movement ofthe mattress relative to the foundation along at least one of the firstand second axes.
 32. The mattress assembly of claim 31, wherein thecavity is a first cavity defined in the mattress, and wherein thefoundation includes a second cavity in which the fitting is anchored.33. The mattress assembly of claim 32, further comprising a fanpositioned in one of the first and second cavities for generating anairflow through the mattress and the foundation.
 34. The mattressassembly of claim 31, wherein the fitting extends between a top surfaceof the foundation and a bottom surface of the mattress.
 35. The mattressassembly of claim 31, wherein the fitting includes a tapered end tofacilitate insertion into the cavity.
 36. The mattress assembly of claim31, wherein the mattress includes a viscoelastic foam.
 37. The mattressassembly of claim 36, wherein a substantial portion of the mattress ismade of the viscoelastic foam.
 38. The mattress assembly of claim 36,wherein the viscoelastic foam includes a hardness of at least about 20 Nand no greater than about 80 N.
 39. The mattress assembly of claim 36,wherein the viscoelastic foam includes a density of no less than about30 kg/m³ and no greater than about 150 kg/m³.